The core technical principle of the vacuum heat setting integrated equipment is analyzed, and its outstanding performance in solving the five core issues of uniformity, energy consumption, sensitive material handling, environmental protection and safety is specifically addressed.
In the fierce market competition, every detail of the production process is crucial to success or failure. In response to the inherent pain points in the heat setting process, our company, relying on its profound engineering and technological accumulation, has launched a revolutionary vacuum heat setting integrated equipment. Now, let's take a look at how it precisely "breaks the deadlock" from a technical perspective.
Pain point one: The uneven temperature in traditional heat setting leads to unstable product quality
Our solution: Adopt a vacuum combined with a plate/radiant heating system.
Technical principle: In a vacuum environment, the uneven heat caused by air convection is eliminated. We conduct bidirectional and uniform radiation heat transfer on materials through carefully designed heating plates or infrared radiation systems. Heat does not need to pass through the air medium but directly penetrates the vacuum to act on the entire material, ensuring an extremely small temperature difference from the surface layer to the core layer, thereby achieving ultimate dimensional stability and physical consistency.
Pain point two: Huge energy consumption and increasing production cost pressure
Our solutions: "Low-temperature evaporation" and "stepwise utilization of thermal energy" technologies.
Technical principle
Low-temperature evaporation: In a vacuum environment, water can boil at 40-60℃. Compared with the traditional hot air drying above 100℃, the preheating energy consumption is significantly reduced.
Heat energy recovery: The system is equipped with a highly efficient heat recovery device. The latent heat released when the large amount of low-temperature steam generated during the drying stage is condensed can be recovered for preheating the feed or as an auxiliary heat source in the heat setting zone, achieving the recycling of energy and having an extremely high comprehensive energy efficiency ratio.
Pain point three: High value-added and heat-sensitive materials cannot be processed
Our solution: An oxygen-free and low-temperature process environment.
Technical principle: Vacuum means no oxygen. This is crucial for handling materials that are prone to oxidation and sensitive to high temperatures. For instance, in the processing of aerospace composite materials, medical polymer fabrics, and special engineering plastics, our equipment can perfectly achieve the complete removal of solvents and the shaping of molecular chains under conditions far below their decomposition temperatures, avoiding yellowing and performance damage.
Pain point Four: Environmental protection emissions do not meet standards, posing safety hazards
Our solution: Fully sealed vacuum system with VOCs centralized treatment interface.
Technical principle: The entire drying and setting process is completed in a sealed container. All volatile solvents and water vapors are uniformly drawn to the condensation system, and high-boiling-point solvents are directly liquefied and recovered. The remaining small amount of non-condensable gas (VOCs) has a high concentration and a small air volume, which greatly reduces the investment and operation costs of subsequent waste gas treatment devices (such as RTO incineration). Meanwhile, an oxygen-free environment fundamentally eliminates the risks of combustion and explosion.
Pain point five: The production process is lengthy and occupies a large area
Our solution: Integrated design.
Technical principle: We have adopted a modular integrated design for the vacuum drying chamber and the heat setting box body. The materials complete the entire process of "drying - preheating - setting - cooling" in a closed system in sequence, achieving single-machine automation. This not only shortens the material transmission time, enhances production efficiency, but also significantly reduces the equipment floor space and optimizes the workshop layout.
Vacuum heat setting equipment: Core technical parameters
Vacuum range: Customizable from rough vacuum to medium and high vacuum
Operating temperature: Room temperature to 300℃ (customizable according to process requirements)
Heating methods: Hot oil/steam/electric heating plate, infrared radiation (optional)
Control system: Fully automatic PLC control, formula management, and real-time recording of process data
We are committed to providing tailor-made optimal solutions for every industry challenge. We welcome you to contact us with specific material and process requirements. We will provide you with a detailed technical feasibility analysis and economic benefit assessment report.